Pelletized shortening

ABSTRACT

A pelletized shortening is prepared by a process which includes melting, cooling, solidifying and extruding natural and/or synthetic shortening materials to provide shortening pellets or chunks which, without requiring further processing, resist clumping together at at least moderate temperatures of about 70° F. (about 21° C.). The pelletized shortening has a hardness or solids profile which is especially suitable for baking applications and imparts a tenderizing effect in bakery type products while still providing a shortening in a form that is easy to handle inasmuch as it is pourable or able to be metered in a flowing particulate style. While it has relatively high solids at room temperature or storage conditions, the solids content of the pelletized shortening dissipates rapidly enough such that the solids reduction will provide the desired tenderizing effect in dough products including biscuits and pizza crusts.

CROSS REFERENCE TO RELATED APPLICATION

This is a continuation-in-part of application Ser. No. 08/704,117, filedAug. 28, 1996 now U.S. Pat. No. 5,866,187.

BACKGROUND AND DESCRIPTION OF THE INVENTION

This invention generally relates to shortening in the form of solidssuch as pellets or chunks. The shortening is primarily vegetable oil orlow-fat or fat substitute, or combination thereof, in a solid formsuitable for uses requiring a non-liquid which is still able to bepoured or metered. More particularly, the invention relates topelletized shortening and the like which resists clumping under roomtemperature conditions which are encountered in many uses. The pelletsare formed by extruding a flow of solidified shortening throughextrusion orifices which impart a desired pellet size and shape uponpassing therethrough.

Pourable shortening products are generally known. In one approach,shortening has been frozen and passed through a meat grinder in aneffort to obtain solid shortening pellets. This approach is somewhatdifficult and not particularly satisfactory such as from the point ofview of consistency of product. Another approach is exemplified by U.S.Pat. No. 4,469,710. Hydrogenated fats are heated, rapidly chilled,treated and formed into small segments or pieces which are said to beparticularly resistant to agglomeration at elevated temperatures. Suchproducts can require involved processing conditions and equipment andcan produce products having higher solid fat indices than required ordesired for certain applications, particularly baking applications.

In accordance with the present invention, pelletized shortening isprovided and prepared by cooling molten shortening materials, forexample partially hydrogenated vegetable oil or a lipid-like fatsubstitute, solidifying same to a desired extent, flowing the cooled andsolidifying shortening material through an elongated tube to form a flowof solid shortening within the elongated tube, and passing the flow ofsolid shortening through a plurality of orifices at a downstream endportion of the elongated tube to thereby extrude the solid shorteningflow through the orifices as a plurality of shortening pellet flowswhich are each of a cross-sectional area which is reduced from that ofthe flow through the elongated tube, thus forming the shorteningpellets. The solid shortening pellets, without requiring any furthertreatment, resist clumping together at a temperature of at least about70° F.

It is accordingly a general object of the present invention to providean improved process, apparatus, and pelletized shortening preparedthereby.

Another object of the present invention is to provide an improvedshortening in the form of chunks or pellets which can be poured ormetered and used for creating special effects in baking operations, suchas a tenderizing effect in dough products.

Another object of this invention is to provide an improved pelletizedshortening which resists clumping together at a temperature of at leastabout 70° F. while having a solid fat index profile that is tailored forparticular end uses.

Another object of the present invention is to provide an improved,simplified process and apparatus for extruding shortening materialdirectly into pellets.

These and other objects, features and advantages of the presentinvention will be apparent from and clearly understood through aconsideration of the following detailed description.

BRIEF DESCRIPTION OF THE DRAWINGS

In the course of this description, reference will made to the attacheddrawings, wherein:

FIG. 1 is a generally schematic elevational view of a preferredembodiment of an apparatus for carrying out the process;

FIG. 2 is a detailed view of an extrusion plate for making relativelylarge sized shortening pellets; and

FIG. 3 is a detailed view of an extrusion plate for making relativelysmall sized shortening pellets.

DETAILED DESCRIPTION OF THE INVENTION

The preferred apparatus illustrated in FIG. 1 includes a feed tank 11for developing a flow of molten shortening, a chilling and crystallizingdevice 12, a resting tube unit 13, and a scaling and packaging assembly14. These shortening materials when referred to herein encompassvegetable oils, low-fat substitutes and fat substitutes. Included arelipid-like fat substitutes and polyol substitutes such as sucrosepolyester (available as OLESTRA® and OLEAN®) and esterified propoxylatedglycerols. Combinations are possible, such as partly polyol substituteand partly triglyceride material.

In an illustrated embodiment, the shortening material is a vegetableoil, typically partially hydrogenated vegetable oil. Initially, thisvegetable oil is raised to a temperature such that it is liquified oremulsified. Feed tank 11 receives a batch of this shortening material,or a flow of same is provided by such a tank or by an assembly withheating capabilities. When within the feed tank 11 or an analogousvessel or assembly, the molten shortening is at a temperature of about110-150° F., which temperature can vary somewhat depending theparticular make-up of the vegetable oil or other shortening material. Inany event, at this stage of this example, there is provided a supply,whether in the form of a flow or a batch, of molten vegetable oil, theoil being at a temperature above its melting point.

This molten shortening material flows through a conduit 15 or the likeand into the chilling and crystallizing device 12. Within this device,the temperature of the shortening material is reduced so that the it ischilled in order to develop seeds of crystalline shortening which willeventually develop so as to solidify the shortening during the process.Preferably, this chilling will be in combination with agitation in orderto promote uniform crystal development while the shortening material iswithin the chilling and crystallizing device 12. This flow of, forexample, vegetable oil containing crystals exits through conduit 16. Atthis point, the vegetable oil or other shortening material shouldexhibit the proper degree of solidification or crystallization. Atypical target in this regard would be between about 25% and about 35%solids within the flow of solidifying shortening material out of theexit conduit 16. If this target has been achieved, the shorteningmaterial is allowed to flow into the resting tube unit 13 or the like,such as by passing through a valve 17 which is thus in an opencondition. Solidification will then be completed, as discussed infurther detail herein.

If the solidifying vegetable oil or other shortening material is not atthe target solids level, it preferably will be directed back into thefeed tank device 11. An illustrated system for achieving this objectiveis a recycle assembly 18. In this arrangement, when the valve 17 isclosed or partially closed, all or a portion of the flow of shorteningmaterial is allowed to divert through diverter passage 19 for eventualreturn to the feed tank 11 through recycle entrance 21 so as to againmelt the shortening material prior to its eventual return flow throughthe chilling and crystallizing device 12. Monitoring of the solidspercentage can be achieved by a suitable approach such as sampling bleedline 22. If the target solids level is being achieved and maintained,recycling will not occur, such as by closing valve 23 of the recycleassembly.

The chilling and crystallizing device 12 will be at a temperature ofbetween about 55 and 95° F. (about 12.8 and 35° C.), depending upon thevegetable oil or other shortening material being processed, theparticular type of chilling and crystallizing device, and the type ofequipment downstream of it, especially the length and volume of theelongated tube 20 of the resting unit. Exemplary chilling andcrystallizing devices include Votator devices, Gerstenberg chillers,Kombinator units (trademarks), and the like.

The thus cooled and crystallizing partially solidified vegetable oil orother shortening material which is within the target solids content nextflows into and through the resting tube unit 13. This unit providesadditional time and physical space to allow crystallization andsolidification to continue. An objective is to have all or most of theheat of crystallization removed from the solidifying shortening flow bythe time the shortening material reaches the downstream end of theresting tube unit 13. This effect can be facilitated by appropriate heattransfer assemblies or devices and can also be affected by the diameteror cross-sectional area of the elongated tube 20. For example, the unit13 can be jacketed whereby the heat of crystallization can be reduced byheat transfer with a flowing, cooling liquid. By the time the shorteningmaterial reaches the downstream end portion of the elongated tube 20 ofthe resting unit 13, it takes the form of a flow of solidifiedshortening. Typical flow times in this regard are at least approximately1 minute, often at about 2 minutes and above such as about 10 minutes.

This solid shortening flow passes through a plurality of orifices atthis downstream end portion of the elongated tube. Each orifice willhave a diameter or cross-sectional area which is substantially less thanthat of elongated tube. By this approach, the solid shortening is forcedto, within and through the plurality of orifices so as to be extrudedinto elongated strands or extruded rods 25. The result is the directformation of shortening pellets 24. By the time of this extrusion stage,the shortening processing has been completed to the extent that thepellets 24 are in a condition to be packaged without further treatment.

In most instances, the pellets 24 are automatically provided to thedesired length due to the influence of gravity upon the narrowed,elongated strands of solid shortening exiting from the resting tube unit13. In other words, once the extruded shortening passes out of the unit13, it is no longer supported. Once the extrusion achieves a reasonablypredictable length, it will move downwardly until it breaks off from theextruded flow. This is generally illustrated in FIG. 1 after theshortening pellets 24 break off and are formed from the extrusion rods25. The resulting shortening pellets 24 can be collected, such as withthe assistance of a hopper 26, and moved onto the scaling and packagingline 14. If desired, an optional cutter 27 can be included when itdesired to ensure that shortening pellets of a uniform length areprepared.

In the preferred resting tube unit 13 which is illustrated, thedownstream end takes the form of a sieve plate or extrusion plate 28.Illustrative plates in this regard are shown in somewhat greater detailin FIG. 2 and in FIG. 3. Extrusion plate 28 in FIG. 2 has a plurality oforifices 29. In this embodiment, each would have an internal diameter ofabout 0.5 inch (about 13 cm). This embodiment also illustrates that theorifices can include a sloped surface 30 on the pressure (upstream) sideof the plate 28. The sloped surfaces 30 are in the nature of a chamferor arcuate beveled edge, although the shape of the holes does notnecessarily have to be circular. This sloping reduces the sharp edgeupon which the shortening would otherwise impinge. A result is alowering of the pressure drop causing less work-softening (and lessstickiness) on the surface of the extruded solids. Sieve plate 28aillustrated in FIG. 3 includes a plurality of orifices 31, each having adiameter of about 0.25 inch (about 6.3 cm). By contrast, a typical innerdiameter of the longitudinal tube of the resting tube unit 13 is betweenabout 4 inches (100 cm) and about 8 inches (200 cm).

A reduction ratio (on the basis of diameters) of the elongated tube tothe extrusion orifices ranges between about 50 to 1 and about 5 to 1,preferably between about 32 to 1 and about 8 to 1. With this approach,the properly solidified shortening will be further solidified bycompaction pressures generated as the shortening component is forcedthrough the relatively much smaller openings in finally forming theshortening pellets 24.

With reference to the scaling and packaging line 14 which is generallyillustrated, it can include a conveyor 32 having a scale component 33 ofa type generally well known in the art. Individual packaging componentssuch as paperboard boxes 34 are conveyed to a location under the hopper26. Each package 34 is filled until the proper weight is attained, afterwhich the thus filled package is conveyed away, and subjected to typicalclosing and sealing procedures and equipment in accordance withgenerally known practices.

With reference to the shortening pellets which are prepared inaccordance with the present invention, they can be considered as chunksor pellets which are able to be poured or metered such as duringindustrial or institutional baking or cooking procedures. When theshortening is vegetable originating, the vegetable oil typically will beprimarily oil component such as soybean oil, cottonseed oil, peanut oil,corn oil, combinations thereof and the like. Typically, the oil will bepartially hydrogenated prior to heating. Depending upon the desiredultimate use for the shortening pellets, they can include minorcomponents such as coloring agents or flavoring agents; for example,beta carotene can be added to impart a yellow color when it is desiredthat the shortening pellets have a butter-like appearance and/or taste.

After processing, the shortening material in its shortening pellet orsolidified form will have a melting point (Mettler Dropping Point) ofbetween about 110° and about 120° F. (about 43.3 and about 48.9° C.),this melting point depending somewhat upon the desired ultimate end usefor the shortening pellets. The shortening pellets have a typical matrixof solids content ranges (solids fat contents or SFC as measured by NMR)as follows:

    ______________________________________                                        Temperature    Percent Solids (SFC)                                           ______________________________________                                        50° F. (10° C.)                                                                53% to 85%                                                     70° F. (21.1° C.)                                                              35% to 65%                                                     80° F. (26.7° C.)                                                              27% to 60%                                                     92° F. (33.3° C.)                                                              20% to 50%                                                     100° F. (37.7° C.)                                                             13% to 35%                                                     104° F. (40° C.)                                                                7% to 20%                                                     110° F. (43.3° C.)                                                              3% to 14%                                                     ______________________________________                                    

Shortening pellets provided in accordance with the present invention areparticularly useful as baking shortenings. When blended with and/orfolded in, they impart special flakiness and a layered texture andconsistency because of their relative size and solid characteristics.The pellets can have a length of about 2 inches to about 3 inches (about50 cm to about 75 cm), although even greater lengths can be possible asdesired, perhaps even as long as about 6 inches to about 8 inches (about150 cm to about 200 cm). The pellets will typically be used in theirsolid, perhaps even refrigerated, state. For example, the pelletizedshortening is found to be particularly useful in certain bakingprocedures which demand separate integrity between the fat and the doughingredients until the baking process has progressed enough to ensure aflaky result. A similar observation can be made with respect to bakingbiscuits and the like. It is important in these types of uses that theshortening pellets are not too hard or solid, such that they might notmelt well enough in the particular baking use. This potentially is aconcern in the lighter baking formulations. In addition to theseadvantages in baking, the shortening pellets can be used in othercooking applications where convenience and easy handling is of interest.Non-baking uses include deep frying of donuts and the like, wherein theuser can simply "pour" the shortening pellets into the deep fryer.

When used in baking, the shortening pellets will comprise approximately5% to approximately 25% by weight of a particular dough formulation. Ingeneral, dough formulations consist of flour components, and one or moreof sweetening components such as sugar, syrups and artificialsweeteners, egg components, milk components and water. Exemplary doughscan be formulated for biscuits, cakes, cookies, pie crusts, pizzacrusts, rolls and the like. The pellets thus used impart a tenderizingquality in these bakery types of products.

The following Examples generally illustrate certain aspects of theinvention.

EXAMPLE 1

An apparatus as generally illustrated in FIG. 1 included a SchroderKombinator as the chilling and crystallizing device. A manual diversionvalve was installed between this unit and the resting tube. A remeltreturn line was set up. Partially hydrogenated soybean oil was combinedwith approximately 1% of coloring and other minor ingredients. A batchof about 5000 pounds of the vegetable oil blend at about 145° F. (62.8°C.) was pumped from the storage tank for providing the emulsion to theKombinator unit. Recycle to a remelt tank and return to the Kombinatorunit was carried out until the vegetable oil was about 30% solids. TheKombinator unit was at 80° F. (about 26.7° C.), and the flow rate wascontrolled by a high pressure pump. The resting tube had a sieve platewith 206 holes, each having a diameter of about 0.5 inch (about 13 cm).The resting tube had a length of about 9 feet (about 2.7 m). At a flowrate of 4500 to 5000 pounds per hour, the solidifying vegetable oilwhich flowed out of the cooling and agitating zone of the Kombinatorunit remained in the resting tube for an average of about 2 minutes and15 seconds.

The resulting shortening chunks had a diameter of 0.5 inch (13 cm) and alength of about 2 to 3 inches (about 50 to 75 cm), although some shorterchunks were also formed. With the minor additions to the formulation,the color and flavor was characterized as buttery. Its Mettler DroppingPoint (melt point) was 112° F. (44.4° C.), and its Iodine Value was 65.Solid fat index analyses indicated 58 units at 50° F. (10° C.), 48 unitsat 70° F. (21.1° C.), 45 units at 80° F. (26.7° C.), 31 units at 92° F.(33.3° C.) and 12 units at 104° F. (40° C.).

EXAMPLE 2

A vegetable oil composition is prepared with hydrogenated soybean oilhaving added flavor and color components, including beta carotene,anhydrous citric acid and artificial flavor. The hydrogenated oil isdeodorized, and the citric acid is added during deodorization, theflavor and color components being added after deodorization. This ispassed through an apparatus generally as discussed in Example 1. Here,the length of the resting tube is about 17 feet (about 5.2 m). Thispermits a resting time of about 4 minutes at a flow rate of 4500 poundsper hour. The temperature of the chilling and crystallizing device issomewhat higher than that of Example 1 due in large measure to thelonger length of the resting tube unit. This temperature is about 87° F.to 88° F. (about 30.6° C. to about 31.1° C.). Resulting pellets have adiameter of 0.5 inch (about 13 cm) and a capillary melting point of111.5° F. (about 44° C.). The solid fat index at 50° F. (10° C.) is 63units. At 70° F. (21.1° C.), it is 52.5 units. At 80° F. (26.7° C.) itis 47.5 units. At 92° F. (33.3° C.) it is 30.5 units, and at 104° F.(40° C.) it is 9 units.

EXAMPLE 3

Shortening pellets designed particularly for biscuit dough formulationswere prepared generally in accordance with the present invention. At 10°C., the solids content (SFC) as measured by NMR was 83.3%. At 21.1° C.,it was 64.8%. At 26.7° C., it was 57.8%. At 33.3° C., it was 46.1%units. At 37.7° C., it was 32.5%. At 43.3° C., the NMR-measured SFCsolids content was 11.7%.

The unblended formulation for making the solid pellets in accordancewith the above was modified so as to incorporate 80% of that formulationblended with 20% of an existing shortening product of lower hardnessvalues (VREAM VFD of Bunge Foods Corporation). This 80/20 blend provideda slightly softer, but generally acceptable product for biscuit uses. Itanalyzed as follows. It had a NMR-measured SFC solids content of 79% at10° C., of 60% at 21.1° C., of 51.9% at 26.7° C., of 41.9% at 33.3° C.,of 30.8% at 37.7° C., and of 11% at 43.3° C.

A similar blend, but this one incorporating 50% of the unblendedsolidified vegetable oil and 50% VREAM VFD, was prepared. ItsNMR-measured SFC solids content values were 69.1% at 10° C., 48.5% at21.1° C., 40.7% at 26.7° C., 26.9% at 33.3° C., 16.8% at 37.7° C., and2.9% at 43.3° C.

A clumping test was conducted. None of these three products exhibitedsignificant clumping when held at 90° F. for in excess of two months. Itwas generally observed that the products having a harder consistency,exhibited similar properties for even longer time periods.

It will be understood that the embodiments of the present inventionwhich have been described are illustrative of some of the applicationsof the principles of the present invention. Numerous modifications maybe made by those skilled in the art without departing from the truespirit and scope of the invention.

What is claimed is:
 1. A baking formulation comprising: between about 75and about 95 weight percent of a dough formulation including a flourcomponent, at least one of a sweetening component, an egg component, amilk component, and a water component; and between about 5 and about 25weight percent of a shortening component which is a pelletizedshortening made by a process comprising the steps of:providing a moltenshortening composition at a temperature above the melting point of thecomposition, allowing cooling of said molten composition to a cooledcomposition at a crystallization temperature at which said shorteningcomposition begins to solidify, flowing said cooled shorteningcomposition through an elongated tube for about 2 minutes to about 10minutes and above while solidifying said cooled composition, therebyforming a flow of solid shortening composition within the elongatedtube, passing said flow of solid shortening composition through aplurality of orifices at a downstream end portion of the elongated tube,said orifices each having a cross-sectional area less than that of theelongated tube, thereby extruding the solid shortening compositionthrough the orifices as solid shortening pellets which are of reducedcross-sectional area and of reduced length when compared with thecross-sectional area and length of the elongated tube, and therebyproviding solidified shortening pellets which, without requiring furthertreatment, resist clumping together at a temperature of at least about70° F.; and said solidified shortening pellets have solids contentvalues as measured by NMR of between about 27% and about 60% at 80° F.(26.7° C.), of between about 20% and about 50% at 92° F. (33.3° C.), ofbetween about 13% and about 35% at 100° F. (37.8° C.), of between about7% and about 20% at 104° F. (40° C.), and of between about 3% and about14% at 110° F. (43.3° C.).
 2. The baking formulation in accordance withclaim 1, wherein said solidified shortening pellets have a MettlerDropping Point of between about 110° and about 120° F. (between about43.3° C. and about 48.9° C.).
 3. The baking formulation in accordancewith claim 1, wherein said temperature of the cooling step is betweenabout 55° F. and about 95° F. (between about 12.8° C. and about 35° C.).4. The baking formulation in accordance with claim 1, wherein thecross-sectional area of the elongated tube and the reducedcross-sectional area of the orifices are at a ratio, based on aninternal diameter measurement, of between about 50 to 1 and about 5to
 1. 5. The baking formulation in accordance with claim 1, wherein saidsolidified shortening pellets have solids content values as measured byNMR of (a) between about 53% and about 85% at 50° F. (10° C.), (b) ofbetween about 35% and about 65% at 70° F. (21.1° C.), or of both (a) and(b).
 6. A baking formulation including: between about 75 and about 95weight percent of a dough formulation including a flour component, ashortening component and at least one of a sweetening component, an eggcomponent, a milk component, and a water component; and said shorteningcomprises:a pelletized shortening of solidified shortening pelletswhich, without requiring further treatment, resist clumping together ata temperature of at least about 70° F.; and said solidified shorteningpellets have solids content values as measured by NMR of between about27% and about 60% at 80° F. (26.7° C.), of between about 20% and about50% at 92° F. (33.3° C.), of between about 13% and about 35% at 100° F.(37.8° C.), of between about 7% and about 20% at 104° F. (40° C.), andof between about 3% and about 14% at 110° F. (43.3° C.).
 7. The bakingformulation in accordance with claim 6, wherein said solidifiedshortening pellets have a Mettler Dropping Point of between about 110°and about 120° F. (between about 43.3° C. and about 48.9° C.).
 8. Thebaking formulation in accordance with claim 6, wherein said solidifiedshortening pellets have solids percentage values of (a) between about53% and about 85% at 50° F. (10° C.), (b) of between about 35% and about65% at 70° F. (21.1° C.), or of both (a) and (b).
 9. A pelletizedshortening made by a process comprising the steps of:providing a moltenshortening composition at a temperature above the melting point of thecomposition, allowing cooling of said molten composition to a cooledcomposition at a crystallization temperature at which said shorteningcomposition begins to solidify, flowing said cooled shorteningcomposition through an elongated tube for about 2 minutes to about 10minutes and above while solidifying said cooled composition, therebyforming a flow of solid composition within the elongated tube, passingsaid flow of solid shortening composition through a plurality oforifices at a downstream end portion of the elongated tube, saidorifices each having a cross-sectional area less than that of theelongated tube, thereby extruding the solid shortening compositionthrough the orifices as solid shortening pellets which are of reducedcross-sectional area and of reduced length when compared with thecross-sectional area and length of the elongated tube, and therebyproviding solidified shortening pellets which, without requiring furthertreatment, resist clumping together at a temperature of at least about70° F.; and said solidified shortening pellets have solids contentvalues as measured by NMR of between about 53% and about 85% at 50° F.(10° C.), of between about 35% and about 65% at 70° F. (21.1° C.), ofbetween about 27% and about 60% at 80° F. (26.7° C.), of between about20% and about 50% at 92° F. (33.3° C.), of between about 13% and about35% at 100° F. (37.8° C.), of between about 7% and about 20% at 104° F.(40° C.), and of between about 3% and about 14% at 110° F. (43.3° C.).10. The pelletized shortening in accordance with claim 9, wherein saidsolidified shortening pellets have a Mettler Dropping Point of betweenabout 110° and about 120° F. (between about 43.3° C. and about 48.9°C.).
 11. The pelletized shortening in accordance with claim 9, whereinsaid temperature of the cooling step is between about 55° F. and about95° F. (between about 12.8° C. and about 35° C.).
 12. The pelletizedshortening in accordance with claim 9, wherein the cross-sectional areaof the elongated tube and the reduced cross-sectional area of theorifices are at a ratio, based on an internal diameter measurement, ofbetween about 50 to 1 and about 5 to
 1. 13. A pelletized shorteningcomprising:a shortening composition which had been melted, cooled,solidified and extruded into pellets, said pellets having a MettlerDropping Point of between about 110° F. and about 120° F. (between about43.3° C. and about 48.9° C.); said shortening pellets have a solidscontent as measured by NMR of between about 27% and about 60% at 80° F.(26.7° C.), of between about 20% and about 50% at 92° F. (33.3° C.), ofbetween about 13% and about 35% at 100° F. (37.8° C.), of between about7% and about 20% at 104° F. (40° C.), and of between about 3% and about14% at 110° F. (43.3° C.); and said shortening pellets, withoutrequiring treatment, resist clumping together at a temperature of atleast about 70° F. (21.1° C.).